The disclosed invention relates to pattern generation, direct-write lithography and to optical writing of patterns on a photosensitive surface in general. In particular it relates to the patterning of photomasks, wafers, printed circuit boards (PCBs), fine-pitch interconnection substrates, flexible substrates with or without active components (transistors) and/or of panels for displays, photovoltaics and illumination. Other patterns with line widths from 0.03 to 10 microns may also use the technology disclosed. In particular the technology relates to high-precision pattern generators and direct writers using acousto-optic modulation.
The subject matter discussed in this section should not be assumed to be prior art merely as a result of its mention in this section. Similarly, a problem mentioned in this section or associated with the subject matter provided as background should not be assumed to have been previously recognized in the prior art. The subject matter in this section merely represents different approaches, which in and of themselves may correspond to implementations of the claimed technology also.
Streaming video from smartphones and tablets require high-resolution displays, which are only possible with the use of advanced manufacturing tools, including laser mask writers for photomask production. Display mask writers are the de facto used in the industry for production of all high-resolution thin film transistor (TFT), liquid crystal display (LCD) and active-matrix organic light-emitting diode (AMOLED) displays worldwide.
Pattern generators are used to write microscopic images onto photomasks which then function as templates for mass production of displays, integrated circuits and electronic packaging. The manufacturing process, called microlithography, is similar to the way in which photographs are reproduced with the help of a negative. A microlithographic laser writer uses a laser beam to pattern a latent image in a photosensitive surface, such as resist on a mask, which is used, in turn, to pattern wafers or large area displays. In the photomask manufacturing industry, stringent requirements are placed on critical dimensions (CD).
Acousto-optic modulation is commonly used in laser scanners, providing a reasonable compromise between cost, speed and efficiency. The laser scanner using an acousto-optic modulator (AOM) may have a single beam or multiple beams and after the modulation of the beam it may be scanned by electro-optic or mechanical means. Prior art exists in the form of polygon scanners, and acousto-optic, all of them employing acousto-optic multibeam modulation.
The pattern line width measurement is a critical dimension (CD) also referred to as edge roughness, which varies as a result of variations in the signal for the laser dose, which is controlled using acousto-optic modulation. An opportunity arises to improve the stability of line widths, and thereby the critical dimensions for pattern generation, direct-write lithography and for optical writing of patterns on a photosensitive surface.
As a first aspect of the invention, there is provided a method of reducing impact of cross-talk between transducers that drive an acousto-optic modulator, abbreviated AOM, including:
operating the transducers, which are coupled to an acousto-optic medium, with different frequencies applied to adjoining transducers and producing a time varying phase relationship between carriers on spatially adjoining modulation channels emanating from the adjoining transducers.
The method may be for reducing impact of cross-talk between transducers that drive an AOM in a microlithographic laser writer.
The AOM may comprise a plurality of transducers. The transducers may be configured for creating an acoustic wave in the acousto-optic medium. The transducers may for example be piezoelectric transducers.
In embodiments, the method is further comprising operating the transducers with the frequencies having differences between pairs of adjoining transducers of at least 100 KHz and a maximum difference of 20 MHz. As an example, the frequency differences between pairs of adjoining transducers may be in a range of 400 KHz to 10 MHz. As a further example, the frequency differences between pairs of adjoining transducers may be less than 5 MHz, such as less than 2 MHz, such as less than 1 MHz, such as less than 500 kHz. As an example, the frequency differences between pairs of adjoining transducers may be between 400 kHz and 1 MHz.
In embodiments, the method comprises operating between 5 and 32 of the transducers to produce 5 to 32 modulation channels in the acousto-optic medium.
In embodiments, the different frequencies between the spatially adjoining modulation channels are arranged in a sawtooth pattern.
In embodiments, the different frequencies between the spatially adjoining modulation channels are arranged in a rising or falling pattern applied progressively to the adjoining transducers.
In embodiments, the different frequencies vary between pairs of adjoining transducers by an amount in a range of plus or minus three percent from an average frequency applied to the transducers.
As a second aspect of the invention, there is provided an acousto-optic modulator, abbreviated AOM, with reduced impact of cross-talk between transducers that are part of the AOM, including:
The AOM may further comprise acoustic absorbers for preventing reflection of waves generated by the transducers back to through the acousto-optic medium.
The acousto-optic medium may for example be silica, quartz or glass.
The AOM may have a beam entrance surface and a beam exit surface. Each transducer may be adapted to modulate a laser beam within a specific modulation zone that traverses the laser beam path between the beam entrance surface and the beam exit surface.
The signal synthesizer may be adapted to generate a radiofrequency signal (RF signal), and the plurality of transducers may be adapted to convert the RF signals from the signal synthesizers into acoustic waves that transverse through the AOM.
In embodiments of the second aspect, the AOM is further including operating the transducers with the frequencies having differences between pairs of adjoining transducers of at least 100 KHz and a maximum difference of 20 MHz. Thus, the signal synthesizer may be configured to operate the transducers with the frequencies having differences between pairs of adjoining transducers of at least 100 KHz and a maximum difference of 20 MHz.
In embodiments of the second aspect, frequency differences between pairs of adjoining transducers are in a range of 400 KHz to 10 MHz. The signal synthesizer may be configured to operate the transducers with frequency differences between pairs of adjoining transducers that are in a range of 400 KHz to 10 MHz.
The phase relationship between spatially adjoining modulation channels may be between ⅔π and 4/3π.
In embodiments of the second aspect, the AOM includes operating between 5 and 32 of the transducers to produce 5 to 32 modulation channels in the acousto-optic medium. The signal synthesizer may be configured to operate between 5 and 32 of the transducers to produce 5 to 32 modulation channels in the acousto-optic medium.
In embodiments of the second aspect, different frequencies between the spatially adjoining modulation channels are arranged in a sawtooth pattern.
In embodiments of the second aspect, the different frequencies between the spatially adjoining modulation channels are arranged in a rising or falling pattern applied progressively to the adjoining transducers.
In embodiments of the second aspect, different frequencies vary between pairs of adjoining transducers in an amount in a range of plus or minus five percent from an average frequency applied to the transducers.
As third aspect of the invention, there is provided a microlithographic laser writer comprising an AOM according to the second aspect above.
As third aspect of the invention, there is provided a microlithographic laser writer configured to perform the method according to the first aspect above.
In the drawings, like reference characters generally refer to like parts throughout the different views. Also, the drawings are not necessarily to scale, with an emphasis instead generally being placed upon illustrating the principles of the technology disclosed. In the following description, various implementations of the technology disclosed are described with reference to the following drawings.
The following detailed description is made with reference to the figures. Sample implementations are described to illustrate the technology disclosed, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a variety of equivalent variations on the description that follows.
A multibeam laser scanner, as known in prior art, is shown in
An acousto-optic modulator (AOM) uses sound waves within a crystal to create a diffraction grating. As the power of the applied RF signal is varied, the amount of diffracted light varies proportionally. Acousto-optic multi-channel modulators allow multiple beams to be modulated independently by integrating an array of transducers with a single acousto-optic crystal.
As used herein, “crosstalk” may refer to acoustic crosstalk and/or electric crosstalk. The electric crosstalk may be capacitive (electrostatic) and/or inductive (electromagnetic).
Under conditions of acoustic crosstalk, sound waves leaking from adjacent AOM channels will interact and create a 3-dimensional pattern such as the one shown in
Experimental results that led to the disclosed technology are described next. Unexpected CD variation was encountered that needed to be diagnosed. The test patterns written to investigate this problem showed a periodic variation in CD accuracy across beams that varied between patterning runs. The periodicity led to investigation of AOM performance and discovery of a problem resulting from cross-talk between neighboring transducers driving modulation channels of the AOM. Careful study and simulation led to an understanding of coherence effects within the AOM crystal that were impacting CD accuracy and to the disclosed approach to addressing the coherence effects that were discovered.
Signal amplitudes for individual beams in the multibeam scan are calculated to give the same exposure dose, and should result in the same line width, written via the different beams. With control over the exposure dose, it is expected that the scanner will measure the same line width, written via different beams.
Researchers used two types of test patterns to evaluate the relative dose in the different exposure beams. For the test patterns, a measure of the exposure dose is the width of the structures exposed by the different beams. Researchers used skew pattern A and measured line width, with only one of the exposure beams on at any given moment.
As a second test with pattern B, researchers used a stable and repeatable transducer input signal and measured line width, with all beams exposed (turned on) at the same time. From job to job the exposure dose did not change. For a multi-channel acousto-optic modulator, some kind of cross-talk is expected when sending acoustic energy into the crystal. In this experiment, 15 transducers were mounted, spaced separated by 0.9 nm, on a single monolithic quartz crystal the size of a sugar cube and fed by independent electronics.
The results for the two test pattern types show very different beam dose signatures. Cross-talk-driven exposure dose variations are not viewable in the static situation in which a single signal is active at any given time. Cross-talk is dependent on the phases of multi-channel input signals. If the phase is random from job to job, then the CD is random from job to job.
Phase-dependent cross talk between acousto-optic modulator (AOM) channels affects the CD: when the phase relationship between neighbor transducer channels changes, the impact on the apparent beam dose changes. In the research example, the 220 MHz carrier signal introduces a random phase relationship between the different transducer beams for each job, which is a cause of the variability between jobs. The phase relationship remained constant during a job but changed between jobs. That is, inter-channel cross-talk between modulators in a multi-channel AOM can have an adverse impact on critical dimensions (CD). When this problem was identified and fixed, the beam dose remained constant over jobs, reducing the impact of acoustic cross-talk between the modulators in the multi-channel AOM and thereby improving the critical dimensions for pattern generation, direct-write lithography and for optical writing of patterns on a photosensitive surface.
Careful study and simulation led to an understanding of coherence effects within the AOM crystal that were impacting CD accuracy. The spread frequency approach transforms static CD differences impacting CD-uniformity, into periodically changing CD along the sweep direction of the pattern writer. Experiments have shown that the nature of the crosstalk in the AOM is strongly dependent on the relative phase of the 220 MHz carrier signal in the different channels. By applying different frequencies in different AOM channels the phase relationship is constantly changing. This in turn modulates the crosstalk signature over time and smears the impact on exposed structures.
When different carrier frequencies are used on the different AOM channels the interference pattern will no longer be static. The interference pattern will travel through the crystal with a speed given by the frequency difference between adjacent AOM channels. The amplitude imprint on the laser beam will change over time and the impact on the exposure result will change as well. If these changes occur quickly enough, the overall impact on the exposure result will be an improvement compared to the default configuration with the same frequency on all channels.
Inter channel crosstalk in a multi-channel AOM causes the phase relationship between neighboring channels to have an impact on the beam dose. The crosstalk may be both electric and/or acoustic crosstalk. During acoustic crosstalk, each beam experiences the effects of an interference wave pattern generated by acoustic energy spread from at least the closest transducer channel in the AOM crystal. With a change in phase of the carrier frequency, the standing wave pattern will move and the impact on the beams will change. With different carrier frequencies on the channels, the standing wave pattern will move and smear the effect over time.
AOM bandwidth affects exposure results, which will benefit from faster moving interference patterns in the AOM crystal achieved by increasing the difference in carrier frequency between adjacent AOM channels. There is a limit to how much the carrier frequency can deviate from the designed 220 MHz utilized in the described example. The limitation can be understood by considering the bandwidth of the AOM and the effects of impedance matching of the electronics in the AOM. Offsetting the carrier frequency very far from the most efficient frequency attenuates the optical transmission, resulting in lower available writing power. This result may be compensated by increasing the laser power. There is however a limit to the feasibility of this approach. Traditionally AOMs have been designed to a narrow bandwidth, according to the classical requirements. Note that the design of the AOM may be changed to increase the bandwidth, enabling a larger spread in carrier frequency.
Simulations led to further understanding of coherence effects, within the AOM crystal, that impact CD accuracy. When many transducers are mounted on a single monolithic quartz crystal, the side-lobes of neighboring transducer signals interact to create a complex interference pattern of sound waves, even when the transducers are fed by independent electronics. The neighboring channel crosstalk impacts the beam dose. The simulation shows the effect of side lobes of nearby transducer signals, with coherence effects caused by the phase relationship of crosstalk between neighboring channels in the multi-channel AOM.
Another simulation of phase relationships on coherence effects within the AOM crystal also led to the disclosed approach for addressing the coherence effects that were discovered. Continuing with phase-based simulations, when the phase of one of the neighbor channels is changed, the geometry of the interference pattern changes.
Next, we describe a computer system usable for generating modulated RF signal 130 for driving the AOM channels.
Computer system 1100 includes at least one central processing unit (CPU) 1172 that communicates with a number of peripheral devices via bus subsystem 1155. These peripheral devices can include a storage subsystem 1110 including, for example, memory devices and a file storage subsystem 1136, user interface input devices 1138, user interface output devices 1176, and a network interface subsystem 1174. The input and output devices allow user interaction with computer system 1100. Network interface subsystem 1174 provides an interface to outside networks, including an interface to corresponding interface devices in other computer systems.
User interface output devices 1176 can include a display subsystem or non-visual displays such as audio output devices. The display subsystem can include an LED display, a flat-panel device such as a liquid crystal display (LCD), a projection device, a cathode ray tube (CRT), or some other mechanism for creating a visible image. The display subsystem can also provide a non-visual display such as audio output devices. In general, use of the term “output device” is intended to include all possible types of devices and ways to output information from computer system 1100 to the user or to another machine or computer system.
Memory subsystem 1122 used in the storage subsystem 1110 can include a number of memories including a main random-access memory (RAM) 1132 for storage of instructions and data during program execution and a read only memory (ROM) 1134 in which fixed instructions are stored. A file storage subsystem 1136 can provide persistent storage for program and data files, and can include a hard disk drive, a floppy disk drive along with associated removable media, a CD-ROM drive, an optical drive, or removable media cartridges. The modules implementing the functionality of certain implementations can be stored by file storage subsystem 1136 in the storage subsystem 1110, or in other machines accessible by the processor.
Bus subsystem 1155 provides a mechanism for letting the various components and subsystems of computer system 1100 communicate with each other as intended. Although bus subsystem 1155 is shown schematically as a single bus, alternative implementations of the bus subsystem can use multiple busses.
Computer system 1100 itself can be of varying types including a personal computer, a portable computer, a workstation, a computer terminal, a network computer, a television, a mainframe, a server farm, a widely-distributed set of loosely networked computers, or any other data processing system or user device. Due to the ever-changing nature of computers and networks, the description of computer system 1100 depicted in
The preceding description is presented to enable the making and use of the technology disclosed. Various modifications to the disclosed implementations will be apparent, and the general principles defined herein may be applied to other implementations and applications without departing from the spirit and scope of the technology disclosed. Thus, the technology disclosed is not intended to be limited to the implementations shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. The scope of the technology disclosed is defined by the appended claims.
Some particular implementations and features are described in the following discussion.
In one implementation, a disclosed method of reducing impact of cross-talk between transducers that drive an acousto-optic modulator (AOM) includes operating the transducers, which are coupled to an acousto-optic medium, with different frequencies applied to adjoining transducers and producing a time varying phase relationship between carriers on spatially adjoining modulation channels emanating from the adjoining transducers.
The method described in this section and other sections of the technology disclosed can include one or more of the following features and/or features described in connection with additional methods disclosed. In the interest of conciseness, the combinations of features disclosed in this application are not individually enumerated and are not repeated with each base set of features. The reader will understand how features identified in this method can readily be combined with sets of base features identified as implementations.
The disclosed method also includes operating the transducers with the frequencies having differences between pairs of adjoining transducers of at least 100 KHz and a maximum difference of 20 MHz. For some implementations of the disclosed method frequency differences between pairs of adjoining transducers is in a range of 400 KHz to 10 MHz.
Some implementations of the disclosed technology include operating between 5 and 32 of the transducers to produce 5 to 32 modulation channels in the acousto-optic medium.
In one implementation of the disclosed method, the different frequencies between the spatially adjoining modulation channels are arranged in a sawtooth pattern.
In another implementation of the disclosed method, the different frequencies between the spatially adjoining modulation channels are arranged in a rising or falling pattern applied progressively to the adjoining transducers.
For some implementations of the disclosed method, the different frequencies vary between pairs of adjoining transducers by an amount in a range of plus or minus three percent from an average frequency applied to the transducers.
For one implementation of the disclosed technology, an acousto-optic modulator (AOM) with reduced impact of cross-talk between transducers that are part of the AOM, includes an acousto-optic medium, a plurality of transducers physically coupled to the acousto-optic medium, spaced apart to drive separate modulation channels within the acousto-optic medium, and a signal synthesizer coupled to the transducers that drives the transducers at different frequencies to produce a time varying phase relationship between spatially adjoining modulation channels.
The disclosed AOM can include operating the transducers with the frequencies having differences between pairs of adjoining transducers of at least 100 KHz and a maximum difference of 20 MHz in one case. In another implementation, the disclosed AOM includes frequency differences between pairs of adjoining transducers in a range of 400 KHz to 10 MHz.
One implementation of the disclosed AOM includes operating between 5 and 32 of the transducers to produce 5 to 32 modulation channels in the acousto-optic medium. For some implementations, the different frequencies between the spatially adjoining modulation channels are arranged in a sawtooth pattern. In other implementations of the disclosed AOM, the different frequencies between the spatially adjoining modulation channels are arranged in a rising or falling pattern applied progressively to the adjoining transducers. In some implementations of the disclosed AOM, the different frequencies vary between pairs of adjoining transducers in an amount in a range of plus or minus five percent from an average frequency applied to the transducers.
The technology disclosed can be practiced as a system, method, or article of manufacture. One or more features of an implementation can be combined with the base implementation. Implementations that are not mutually exclusive are taught to be combinable. One or more features of an implementation can be combined with other implementations.
While the technology disclosed is disclosed by reference to the preferred embodiments and examples detailed above, it is to be understood that these examples are intended in an illustrative rather than in a limiting sense. It is contemplated that modifications and combinations will readily occur to those skilled in the art, which modifications and combinations will be within the spirit of the innovation and the scope of the following claims.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/EP2019/085022 | 12/13/2019 | WO | 00 |
Number | Date | Country | |
---|---|---|---|
Parent | 16221296 | Dec 2018 | US |
Child | 17296739 | US |